140 GC MOTOR GRADER W92.Transmission - Assemble

140 GC Motor Grader W9200001-UP (MACHINE) POWERED BY C7.1 Engine(M0098...
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Producto: MOTOR GRADER

Modelo: 140 GC MOTOR GRADER W92
Configuración: 140 GC Motor Grader W9200001-UP (MACHINE) POWERED BY C7.1 Engine
Desarmado y Armado
140 GC Motor Grader Power Train
Número de medio -M0104787-02 Fecha de publicación -01/03/2020 Fecha de actualización -13/03/2020
i07966218
Transmission - Assemble
SMCS - 3002-016; 3030-016; 3159-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-5750 Engine Stand 1
B 581-9598 Bracket As 1
C - Guide Stud (M8x1.25x80-MM) 2
D 421-5662 Lifting Eye Assembly 2
E 589-7478 Pump Removal Tool Gp 1
F 589-7479 Shaft Removal Tool Gp 1
G 418-4568 Table As 1
H 589-7480 Spring Installer 1
J 589-7481 Shaft Removal Tool 1
1P-0074 Slide Hammer Puller Gp 1
K
4C-5653 Threaded Adapter 1
L 8B-7551 Bearing Puller Gp 1
M 1P-0520 Driver Gp 1
140 GC Motor Grader W9200001-UP (MACHINE) POWERED BY C7.1 Engine(M0098... Page 2 of 75
8T-0355 Bolt 1
N 1U-5230 Hydraulic Pump Assembly 1
360-6956 Hydraulic Cylinder Gp 1
P 369-9451 Grease -
R - Loctite 263 -
6V-2012 Depth Gauge As 1
S
316-1188 Depth Gauge Rod 1
589-7482 Driver 1
T
589-7483 Handle 1
U - Isopropyl Alcohol -
V 589-7485 Seal Installer 1
W - Loctite 243 -
589-7484 Driver 1
X
589-7483 Handle 1
Y 367-9109 Caliper 1
Z 1P-0510 Driver Gp 1
AA 8T-5096 Tool Gp 1
AB 439-3938 Link Bracket 2
AC 589-7486 Pump Installation Tool 1
AD - Guide Stud (M10x1.5x120-MM) 2
Illustration 1 g06471531
Reference: For more information, refer to supplemental video 140 GC Transmission - Assemble on
Caterpillar Channel1 (A CWS login is required to access Caterpillar Channel1)
Note: Click or copy the following link into a web browser (A CWS login is required to access
Caterpillar Channel1), or scan the following QR code with a QR enabled device.
https://channel1.mediaspace.kaltura.com/media/1_o1yvnr3k
1. Apply Tooling (P) to seal rings (171). Install seal rings (171) on shaft assembly (88).
Note: The O-ring seal will be installed at a later Step in the procedure.
4. Apply Tooling (P) to ball (168) for retention purposes. Install ball (168) on shaft assembly (35).
Repeat for the ball on the opposite side of shaft assembly (35).
5. Install O-ring seal (165) on shaft assembly (164).

6. Use Tooling (A) to position transmission (1) as shown in Illustration 7.
7. Use a suitable hammer to install shaft assembly (164).
8. Apply Tooling (R) to the threads of bolt (163). Install the washers and bolt (163).
10. Use a suitable hammer to install shaft assembly (161) until the O-ring seal is inside the housing
for the transmission. Do not fully install shaft assembly (161).
11. Install brake cam (131), washer (128), and retaining ring (127).
12. Use a suitable hammer to finish installing shaft assembly (161) so that there is no end play for
brake cam (131).
13. Apply Tooling (R) to the threads of bolt (160). Install the washers and bolt (160).
Note: Do not overtighten bolt (160). Overtightening bolt (160) will prevent the brake cam from
moving freely.
14. Install breather (159).

15. Install valve (158), piston (157), spring (156), and washer (155) in relief valve assembly (154).
16. Install relief valve assembly (154).
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure

and wear protective equipment.
17. Install the O-ring seal and plug (153).
18. Install the gaskets, tube assembly (151), bolts (152), and bolts (150).
19. Install retaining ring (147).

21. Install shim (148) (not shown) and bearing assembly (149).
22. Use Tooling (M) to finish installing bearing assembly (149).
23. Raise the temperature of race (145) and install race (145) on gear assembly (143).
24. Install cover plate (144).
25. Install gear assembly (143).

26. Apply Tooling (R) to bolt (137). Install cover plate (138) and bolt (137). Tighten bolt (137) to a
torque of 23 N·m (204 lb in).
27. Apply Tooling (R) to bolt (136). Install bolt (136) on cover plate (138). Tighten bolt (136) to a
torque of 23 N·m (204 lb in).
28. Install retaining ring (142) and spacer (141).
29. Install shaft assembly (140).
30. Use Tooling (S) to measure Dimension (D1) as shown in Illustration 30. Dimension (D1) is the
distance between the top of shaft assembly (140) and the contact face of shaft assembly (140)
for the bearing assembly.
distance between the top of shaft assembly (140) and the top face of retaining ring (142).
32. Subtract Dimension (D2) from Dimension (D1). The result will be Dimension (D3). Dimension
(D3) should be 0.30 to 0.50 mm (0.013 to 0.020 inch).
33. If Dimension (D3) is not correct, change shim (148) as needed to obtain the correct
measurement.
34. Remove shaft assembly (140).
35. Position shaft assembly (140) into a suitable press.
36. Use the suitable press to install bearing assembly (146) on shaft assembly (140).
37. Use a suitable heater to raise the temperature of the transmission housing in the locations shown
in Illustration 35 to 90° C (194° F).
Note: Do not use an open flame heater.
38. Install shaft assembly (140).
39. Install shims (139).

41. Apply Tooling (R) to the edges of cover (134) and cover (135) (not shown).
42. Use Tooling (T) to install cover (134) and cover (135) (not shown).
43. Apply Tooling (U) to lip-type seal (132).

44. Use Tooling (V) and a suitable hammer to install lip-type seal (132).
45. Remove retaining ring (127) and washer (128).
injury.

46. Install brake shoes (130) and springs (129).
47. Install washer (128) and retaining ring (127).

48. Install flange assembly (126) and O-ring seal (125).
49. Apply Tooling (W) to the top of the shaft assembly and the threads of bolts (123).
50. Install plate (124) and bolts (123). Tighten bolts (123) to a torque of 46 N·m (34 lb ft) prior to
the installation of lockwasher (122).
51. Use Tooling (X) to install a new lockwasher (122).

52. Install brake drum (121) and bolts (120). Tighten bolts (120) to a torque of 68 N·m (50 lb ft).
54. Apply Tooling (U) to lip-type seal (119).
55. Use Tooling (V) and a suitable hammer to install lip-type seal (119).
56. Install yoke (118) and O-ring seal (117).
57. Apply Tooling (W) to the top of the shaft assembly and the threads of bolts (114).
58. Install plate (116) and bolts (114). Tighten bolts (114) to a torque of 46 N·m (34 lb ft) prior to
the installation of lockwasher (115).
59. Use Tooling (X) to install a new lockwasher (115).
View from inside the transmission
60. Install bearing assembly (109), gear (110), race (111), bearing assembly (112), and shims (113)
in gear assembly (107).
62. Install gear assembly (107).
63. Use a suitable heater to raise the temperature of the bore for shaft assembly (106) to 90° C
(194° F).
64. Install shaft assembly (106) until contact with the housing is obtained.
65. Apply Tooling (W) to the threads of bolt (105). Install bolt (105). Tighten bolt (105) to a torque
of 80 N·m (59 lb ft).
66. Apply Tooling (R) to the outer edge of a new cover (104). Install a new cover (104).
67. Install bearing (66) and retaining ring (65).
68. Apply Tooling (P) to seal ring (64) and seal ring (63). Install seal ring (64) and seal ring (63) on
piston (62).
69. Install piston (62) into clutch assembly (46).
70. Install one guide ring (61), spring (60), and the other guide ring (61) in clutch assembly (46).
injury.

71. Position clutch assembly (46) into a suitable press.
72. Use Tooling (H) and the suitable press to compress the spring and install guide ring (59).
74. Slowly release the pressure on the spring and remove Tooling (H).
Note: The three clutch assemblies for the transmission are similar, but the clutch assemblies are
not the same. Do not interchange the parts for the clutch assemblies.
75. Install friction discs (56) and clutch plates (57).

76. Install shim plate (55) and retaining ring (54) in clutch assembly (46).
Note: This step is used to verify the clutch plate clearance.

distance between the top of shim plate (55) and the top of clutch assembly (46).
Note: This step is used to verify the clutch plate clearance.
78. Use two suitable screwdrivers to pry up on shim plate (55) until suitable contact is made with
retaining ring (54).
distance between the top of shim plate (55) and the top of clutch assembly (46).
80. Add Dimension (D4) and Dimension (D5) together. The sum is Dimension (D6). Dimension
(D6) should be 2.60 to 2.80 mm (0.102 to 0.110 inch).
81. If Dimension (D6) does not equal 2.60 to 2.80 mm (0.102 to 0.110 inch), use Tooling (Y) to
measure retaining ring (54) and top clutch plate (57). Use a new retaining ring (54) and top
clutch plate (57) as needed to obtain the correct measurement.
82. Rotate clutch assembly (46) by 180 degrees.
83. Repeat Step 67 to Step 81 for the opposite side of clutch assembly (46).
84. Install thrust plate (53).
86. Install roller bearing (51) and bearing race (50) into gear (49).
87. Install gear (49) on clutch assembly (46). While installing gear (49), hold roller bearing (51)
and bearing race (50) in place.
88. Install roller bearing (48) and bearing race (47) into gear (49).

91. Install ball bearing (41) and spacer (42) on gear assembly (38).
92. Install shim plate (40) and retaining ring (39) on gear assembly (38).
93. Rotate gear assembly (38) by 180 degrees. Install needle cage (43) in gear assembly (38).
94. Apply Tooling (P) to thrust plate (44) for retention purposes. Install thrust plate (44) in gear
assembly (38).
95. Install gear assembly (38) on clutch assembly (36).
96. Repeat Step 67 to Step 81 for clutch assembly (86).

98. Apply Tooling (P) to thrust plate (84) for retention purposes. Install thrust plate (84) in gear
(83).
99. Install gear (83) on clutch assembly (70).

102. Install roller cage (80) on gear assembly (76).

103. Install seal ring (79) on gear assembly (76). Install seal ring (79) in the orientation that is shown
in Illustration 88.
104. Install seal ring (78) on gear assembly (76). Install seal ring (78) in the orientation that is shown
in Illustration 90.
105. Install roller cage (77) on gear assembly (76).
106. Rotate gear assembly (76) by 180 degrees. Apply Tooling (P) to thrust plate (81) for retention
purposes. Install thrust plate (81) in gear assembly (76).
107. Install gear assembly (76) on clutch assembly (70).
108. Position clutch assembly (70) as shown in Illustration 94.
109. Install needle cage (74) and needle cage (75) (not shown).
110. Repeat Step 67 to Step 81 for clutch assembly (89).

112. Install roller bearing (100) into gear (99).
113. Install bearing race (101) into gear (99).
114. While installing gear (99), hold thrust plate (102) in place.
115. Install gear (99).

118. Install washer (97).
119. Apply Tooling (P) to thrust plate (96). Install thrust plate (96) in gear assembly (94).
120. Rotate gear assembly (94) by 180 degrees. Install needle cage (95) into gear assembly (94).
121. Install roller bearings (93) and gear assembly (94).
122. Position clutch assembly (89) as shown in Illustration 107.
123. Install roller bearing (91) and bearing race (92).

124. Use two people to position clutch assembly (89) onto a flat surface that is suitable for
measuring. The weight of clutch assembly (89) is approximately 32 kg (70 lb).
125. Position Tooling (Z) on clutch assembly (89).
Note: Position Tooling (Z) only on the roller bearings and not on the gear assembly.
126. Use Tooling (S) to measure Dimension (D7) as shown in Illustration 108. Dimension (D7) is
the distance between the top surface of Tooling (Z) to the bottom of clutch assembly (89).
127. Use Tooling (Y) to measure the height of Tooling (Z). The height of Tooling (Z) is Dimension
(D8).
128. Subtract Dimension (D8) from Dimension (D7) to obtain Dimension (D9).
129. Position shaft assembly (88) onto a flat surface that is suitable for measuring.
the distance between the top surface of shaft assembly (88) that contacts the roller bearings of
the clutch assembly to the top of the flange surface of shaft assembly (88).
131. Add Dimension (D9) to Dimension (D10) to obtain Dimension (D11).


the distance between the top surface of the housing for transmission (1) to the top surface of the
bottom of the housing for transmission (1).
133. Subtract Dimension (D12) from Dimension (D11) to obtain Dimension (D13). Dimension
(D13) is the end play for the clutch assembly without the thrust washers. Add thrust washers as
needed to obtain an end play of 0.10 to 0.30 mm (0.004 to 0.012 inch).


134. Use two people to position clutch assembly (89) onto Tooling (G). The weight of clutch
assembly (89) is approximately 32 kg (70 lb).
135. Position Tooling (G) and suitable cribbing under clutch assembly (89) as shown in Illustration
114.
136. Use Tooling (G) to lift clutch assembly (89) and install clutch assembly (89).

137. Use a suitable screwdriver to lift clutch assembly (89). Install shims (90).
138. Lower the temperature of shaft assembly (88) and install O-ring seal (172) on shaft assembly
(88).

(194° F).
140. Use a soft-faced hammer to install shaft assembly (88).
141. Install nuts (87). Tighten nuts (87) to a torque of 23 N·m (204 lb in).


142. Attach Tooling (AA) to clutch assembly (89) as shown in Illustration 121. Use Tooling (AA) to
verify the end play of clutch assembly (89) is 0.10 to 0.30 mm (0.004 to 0.012 inch).
(D15).

148. Position shaft assembly (69) onto suitable cribbing for measuring.

129.
156. Use a suitable screwdriver to lift clutch assembly (70). Install shim (71).

Components removed for photographic purposes
157. Use a suitable screwdriver to lift clutch assembly (70).
158. Install thrust washer (73) as shown in Illustration 134.
159. Use a suitable screwdriver to lift clutch assembly (70). Install thrust washer (72).
(69).
(194° F).
163. Install fittings (67) and nuts (68). Tighten nuts (68) to a torque of 23 N·m (204 lb in).
(D22).

170. Position shaft assembly (35) onto a flat surface that is suitable for measuring.
146.
178. Use a suitable screwdriver to lift clutch assembly (36). Install shims (37).
(35).
(194° F).
182. Apply Tooling (W) to screw plugs (33). Install rollers (34), screw plugs (33), and nuts (32).
Tighten screw plugs (33) to a torque of 10 N·m (89 lb in). Tighten nuts (32) to a torque of
23 N·m (204 lb in).
Note: Rollers (34) are located underneath screw plugs (33).


185. Attach Tooling (AB) and a suitable lifting device to pump assembly (27). The weight of pump
186. Use Tooling (AB) and the suitable lifting device to lift pump assembly (27).
187. Apply Tooling (W) to the inlet ports and outlet ports of pump assembly (27) as shown in
Illustration 157.

188. Attach Tooling (AC) to the housing of transmission (1).
189. Use a suitable heater to raise the temperature of the bore for pump assembly (27) to 90° C
(194° F).
190. Install Tooling (AD) and the gasket for pump assembly (27).
191. Install pump assembly (27).
192. Install gasket (26).

193. Insert bearing assembly (25) and lip-type seal (24) in housing assembly (23).
194. Install Tooling (C).
195. Install housing assembly (23) and bolts (22). Tighten bolts (22) to a torque of 23 N·m
(204 lb in).
196. Use two people to install housing (20). The weight of housing (20) is approximately 14 kg
(30 lb).
197. Install bolts (21). Tighten bolts (21) to a torque of 68 N·m (50 lb ft).
198. Apply Tooling (P) to seal ring (19). Install seal ring (19) on converter assembly (18).
199. Rotate converter assembly (18) by 180 degrees.
200. Attach Tooling (D) and a suitable lifting device to converter assembly (18). The weight of
converter assembly (18) is approximately 27 kg (60 lb).
201. Use Tooling (D) and the suitable lifting device to install converter assembly (18).
202. Apply Tooling (R) to bolts (16). Install plate (17) and bolts (16). Tighten bolts (16) to a torque
of 115 N·m (85 lb ft).
203. If necessary, install new cable straps to secure the converter assembly to transmission (1).

205. Install the gasket, housing assembly (31), and bolts (30). Tighten bolts (30) to a torque of
23 N·m (204 lb in).
206. Install the gasket, cover (29), and bolts (28).
208. Install Tooling (C).
209. Install gasket (13), plate (14), and gasket (15) in plate assembly (12).
Note: Verify the order of the gaskets and plates for proper assembly.
210. Install plate assembly (12).
211. Install duct plate (11) over Tooling (C).
212. Install bolts (10). Tighten bolts (10) to a torque of 20 N·m (177 lb in).
Note: Note the size of the head for bolts (10). Bolts (10) have a shorter head than the head for
bolts (4).
213. Install gasket (7), plate (8), and gasket (9) in plate assembly (6).
Note: Verify the order of the gaskets and plates for proper assembly.
214. Position Tooling (C) as shown in Illustration 175.
215. Install plate assembly (6).

216. Install valve assembly (5).
217. Remove Tooling (C).
218. Install bolts (4). Tighten bolts (4) to a torque of 20 N·m (177 lb in).
Note: Note the size of the head for bolts (4). Bolts (4) have a longer head than the head for
bolts (10).
219. Install hose assemblies (3) and hose assemblies (2).
220. Attach a suitable lifting device to transmission (1). The weight of transmission (1) is
approximately 454 kg (1000 lb).
221. Remove Tooling (B) from transmission (1). Position transmission (1) away from Tooling (B)
and Tooling (A).
222. Remove Tooling (B) from Tooling (A).
End By:
a. Install the transmission.
Copyright 1993 - 2021 Caterpillar Inc. Fri Nov 5 19:27:02 EST 2021
Todos los derechos reservados.
Red privada para licenciados del SIS.

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140 GC Motor Grader W9200001-UP (MACHINE) POWERED BY C7.1 Engine(M0098...

Producto: MOTOR GRADER

5. Install O-ring seal (165) on shaft assembly (164).

6. Use Tooling (A) to position transmission (1) as shown in Illustration 7.

7. Use a suitable hammer to install shaft assembly (164).

9. Install O-ring seal (162) on shaft assembly (161).

14. Install breather (159).

16. Install relief valve assembly (154).

To prevent possible injury, follow the established assembly procedure

17. Install the O-ring seal and plug (153).

19. Install retaining ring (147).

22. Use Tooling (M) to finish installing bearing assembly (149).

24. Install cover plate (144).

25. Install gear assembly (143).

28. Install retaining ring (142) and spacer (141).

29. Install shaft assembly (140).

34. Remove shaft assembly (140).

35. Position shaft assembly (140) into a suitable press.

Note: Do not use an open flame heater.

38. Install shaft assembly (140).

39. Install shims (139).

40. Install retaining ring (133).

43. Apply Tooling (U) to lip-type seal (132).

45. Remove retaining ring (127) and washer (128).

To prevent possible injury, follow the established assembly procedure

46. Install brake shoes (130) and springs (129).

47. Install washer (128) and retaining ring (127).

48. Install flange assembly (126) and O-ring seal (125).

51. Use Tooling (X) to install a new lockwasher (122).

54. Apply Tooling (U) to lip-type seal (119).

56. Install yoke (118) and O-ring seal (117).

59. Use Tooling (X) to install a new lockwasher (115).

61. Install O-ring seal (108) on shaft assembly (106).

62. Install gear assembly (107).

Note: Do not use an open flame heater.

67. Install bearing (66) and retaining ring (65).

69. Install piston (62) into clutch assembly (46).

To prevent possible injury, follow the established assembly procedure

71. Position clutch assembly (46) into a suitable press.

73. Install retaining ring (58).

75. Install friction discs (56) and clutch plates (57).

Note: This step is used to verify the clutch plate clearance.

Note: This step is used to verify the clutch plate clearance.

82. Rotate clutch assembly (46) by 180 degrees.

84. Install thrust plate (53).

85. Install thrust plate (52).

89. Rotate clutch assembly (46) by 180 degrees.

90. Install thrust plate (45).

95. Install gear assembly (38) on clutch assembly (36).

96. Repeat Step 67 to Step 81 for clutch assembly (86).

97. Install thrust plate (85).

99. Install gear (83) on clutch assembly (70).

100. Rotate clutch assembly (70) by 180 degrees.

101. Install thrust plate (82).

102. Install roller cage (80) on gear assembly (76).

105. Install roller cage (77) on gear assembly (76).

107. Install gear assembly (76) on clutch assembly (70).

108. Position clutch assembly (70) as shown in Illustration 94.